Structure and formation method of fin-like field effect transistor

ABSTRACT

A structure and a formation method of a semiconductor device are provided. The semiconductor device includes a semiconductor substrate and a fin structure over the semiconductor substrate. The semiconductor device also includes a gate stack covering a portion of the fin structure and an epitaxially grown source/drain structure over the fin structure and adjacent to the gate stack. The semiconductor device further includes a semiconductor protection layer over the epitaxially grown source/drain structure. The semiconductor protection layer has an atomic concentration of carbon greater than that of the epitaxially grown source/drain structure.

PRIORITY CLAIM AND CROSS-REFERENCE

This Application claims the benefit of U.S. Provisional Application No.62/011,386, filed on Jun. 12, 2014, the entirety of which isincorporated by reference herein.

BACKGROUND

The semiconductor integrated circuit (IC) industry has experienced rapidgrowth. Continuing advances in semiconductor manufacturing processeshave resulted in semiconductor devices with finer features and/or higherdegrees of integration. Functional density (i.e., the number ofinterconnected devices per chip area) has generally increased whilefeature size (i.e., the smallest component that can be created using afabrication process) has decreased. The scaling-down process generallyprovides benefits by increasing production efficiency and loweringassociated costs.

Despite groundbreaking advances in materials and fabrication, scalingplanar devices such as the metal-oxide-semiconductor field effecttransistor (MOSFET) device has proven challenging. To overcome thesechallenges, circuit designers look to novel structures to deliverimproved performance, which has resulted in the development ofthree-dimensional designs, such as fin-like field effect transistors(FinFETs). The FinFET is fabricated with a thin vertical “fin” (or finstructure) extending up from a substrate. The channel of the FinFET isformed in this vertical fin. A gate is provided over the fin to allowthe gate to control the channel from multiple sides. Advantages of theFinFET may include a reduction of the short channel effect, reducedleakage, and higher current flow.

However, since feature sizes continue to decrease, fabrication processescontinue to become more difficult to perform. Therefore, it is achallenge to form a reliable semiconductor device including the FinFET.

BRIEF DESCRIPTION OF THE DRAWINGS

Aspects of the present disclosure are best understood from the followingdetailed description when read with the accompanying figures. It shouldbe noted that, in accordance with the standard practice in the industry,various features are not drawn to scale. In fact, the dimensions of thevarious features may be arbitrarily increased or reduced for clarity ofdiscussion.

FIGS. 1A-1F are perspective views of various stages of a process forforming a semiconductor device, in accordance with some embodiments.

FIGS. 2A-9A are cross-sectional views of various stages of a process forforming a semiconductor device, in accordance with some embodiments.

FIGS. 2B-9B are cross-sectional views of various stages of a process forforming a semiconductor device, in accordance with some embodiments.

FIG. 10 is a cross-sectional view of a process chamber, in accordancewith some embodiments.

FIG. 11 is a cross-sectional view of a stage of a process for forming asemiconductor device, in accordance with some embodiments.

DETAILED DESCRIPTION

The following disclosure provides many different embodiments, orexamples, for implementing different features of the provided subjectmatter. Specific examples of components and arrangements are describedbelow to simplify the present disclosure. These are, of course, merelyexamples and are not intended to be limiting. For example, the formationof a first feature over or on a second feature in the description thatfollows may include embodiments in which the first and second featuresare formed in direct contact, and may also include embodiments in whichadditional features may be formed between the first and second features,such that the first and second features may not be in direct contact. Inaddition, the present disclosure may repeat reference numerals and/orletters in the various examples. This repetition is for the purpose ofsimplicity and clarity and does not in itself dictate a relationshipbetween the various embodiments and/or configurations discussed.

Further, spatially relative terms, such as “beneath,” “below,” “lower,”“above,” “upper” and the like, may be used herein for ease ofdescription to describe one element or feature's relationship to anotherelement(s) or feature(s) as illustrated in the figures. The spatiallyrelative terms are intended to encompass different orientations of thedevice in use or operation in addition to the orientation depicted inthe figures. The apparatus may be otherwise oriented (rotated 90 degreesor at other orientations) and the spatially relative descriptors usedherein may likewise be interpreted accordingly.

Some embodiments of the disclosure are described. FIGS. 1A-1F areperspective views of various stages of a process for forming asemiconductor device, in accordance with some embodiments. Additionaloperations can be provided before, during, and/or after the stagesdescribed in FIGS. 1A-1F. FIGS. 2A-9A are cross-sectional views ofvarious stages of a process for forming a semiconductor device, inaccordance with some embodiments. For example, FIGS. 2A-9A arecross-sectional views taken along the line A-A in FIGS. 1A-1F. FIGS.2B-9B are cross-sectional views of various stages of a process forforming a semiconductor device, in accordance with some embodiments. Forexample, FIGS. 2B-9B are cross-sectional views taken along the line B-Bin FIGS. 1A-1F. Some of the stages described can be replaced oreliminated for different embodiments. Additional features can be addedin the semiconductor device. Some of the features described below can bereplaced or eliminated for different embodiments.

As shown in FIGS. 1A, 2A, and 2B, a semiconductor substrate 100 isprovided. In some embodiments, the semiconductor substrate 100 is a bulksemiconductor substrate. The bulk semiconductor substrate may be asemiconductor wafer such as a silicon wafer. In some embodiments, thesemiconductor substrate 100 includes an elementary semiconductormaterial such as silicon or other elementary semiconductor materialssuch as germanium. In some other embodiments, the semiconductorsubstrate 100 includes a compound semiconductor. The compoundsemiconductor may include silicon carbide, gallium arsenide, indiumarsenide, indium phosphide, another suitable compound semiconductor, ora combination thereof.

In some embodiments, the semiconductor substrate 100 is asemiconductor-on-insulator (SOI) substrate. The SOI substrate may befabricated by using a separation by implantation of oxygen (SIMOX)process, a wafer bonding process, another applicable method, or acombination thereof.

In some embodiments, the semiconductor substrate 100 includes variousdoped regions (not shown) depending on design requirements of thesemiconductor device. The doped regions include, for example, p-typewells and/or n-type wells. In some embodiments, the doped regions aredoped with p-type dopants. For example, the doped regions are doped withboron or BF₂. In some embodiments, the doped regions are doped withn-type dopants. For example, the doped regions are doped with phosphoror arsenic. In some embodiments, some of the doped regions are p-typedoped, and the other doped regions are n-type doped.

Afterwards, one or more fin structures are formed over the semiconductorsubstrate 100. As shown in FIGS. 1A, 2A, and 2B, fin structures 102N₁,102N₂, 102P₁, and 102P₂ are formed, in accordance with some embodiments.In some embodiments, the fin structures 102N₁, 102N₂, 102P₁, and 102P₂are formed by etching into the semiconductor substrate 100. Thesemiconductor substrate 100 is partially removed to form recesses (ortrenches). A photolithography process and an etching process may be usedto form the recesses. As a result, the fin structures 102N₁, 102N₂,102P₁, and 102P₂ are formed between the recesses.

As shown in FIGS. 1A, 2A, and 2B, one or more isolation features 103 areformed over the semiconductor substrate 100, in accordance with someembodiments. The isolation features 103 are used to define andelectrically isolate various device elements formed in and/or over thesemiconductor substrate 100. In some embodiments, the isolation features103 surround lower portions of the fin structures 102N₁, 102N₂, 102P₁,and 102P₂. Upper portions of the fin structures 102N₁, 102N₂, 102P₁, and102P₂ protrude from the top surfaces of the isolation features 103.

In some embodiments, the isolation features 104 include shallow trenchisolation (STI) features, local oxidation of silicon (LOCOS) features,another suitable isolation features, or a combination thereof. In someembodiments, each of the isolation features 104 has a multi-layerstructure. In some embodiments, the isolation features 103 are made of adielectric material. The dielectric material may include silicon oxide,silicon nitride, silicon oxynitride, fluoride-doped silicate glass(FSG), low-K dielectric material, other suitable materials, or acombination thereof. In some embodiments, an STI liner (not shown) isformed to reduce crystalline defects at the interface between thesemiconductor substrate 100 and the isolation features 104.

In some embodiments, a dielectric material layer is deposited over thesemiconductor substrate 100. The dielectric material layer covers thefin structures 102N₁, 102N₂, 102P₁, and 102P₂. In some embodiments, thedielectric material layer is deposited using a chemical vapor deposition(CVD) process, a spin-on process, another applicable process, or acombination thereof. In some embodiments, a planarization process, suchas a chemical mechanical polishing (CMP) process, is performed to thindown the dielectric material layer until the fin structures 102N₁,102N₂, 102P₁, and 102P₂ are exposed. Afterwards, an etching process isperformed to remove an upper portion of the dielectric material layersuch that the fin structures 102N₁, 102N₂, 102P₁, and 102P₂ protrudefrom the remaining dielectric material layer. As a result, the isolationfeatures 103 are formed. This also allows the fin structures 102N₁,102N₂, 102P₁, and 102P₂ to be selectively processed in subsequentoperations.

As shown in FIGS. 1A, 2A, and 2B, one or more gate stacks are formedover the semiconductor substrate 100 and the fin structures, inaccordance with some embodiments. For example, gate stacks 104N and 104Pare formed. Each of the gate stacks 104N and 104P includes a gatedielectric layer 106 and a gate electrode 108, in accordance with someembodiments. In some embodiments, each of the gate stacks 104N and 104Pincludes a hard mask 110. The hard mask 110 is used to assist in theformation of the gate stacks 104N and 104P. In some embodiments, thehard mask 110 is made of silicon oxide, silicon nitride, siliconoxynitride, silicon carbide, another suitable material, or a combinationthereof. In some embodiments, the hard mask 110 has a multi-layerstructure.

In some embodiments, the gate dielectric layer 106 is made of siliconoxide, silicon nitride, silicon oxynitride, dielectric material withhigh dielectric constant (high-K), another suitable dielectric material,or a combination thereof. Examples of high-K dielectric materialsinclude hafnium oxide, zirconium oxide, aluminum oxide, hafniumdioxide-alumina alloy, hafnium silicon oxide, hafnium siliconoxynitride, hafnium tantalum oxide, hafnium titanium oxide, hafniumzirconium oxide, another suitable high-K material, or a combinationthereof. In some embodiments, the gate dielectric layer 106 is a dummygate dielectric layer which will be removed in a subsequent process. Thedummy gate dielectric layer is, for example, a silicon oxide layer.

In some embodiments, the gate electrode 108 includes polysilicon, ametal material, another suitable conductive material, or a combinationthereof. In some embodiments, the gate electrode 108 is a dummy gateelectrode layer and will be replaced with another conductive materialsuch as a metal material. The dummy gate electrode layer is made of, forexample, polysilicon.

In some embodiments, a gate dielectric material and a gate electrodelayer are deposited over the semiconductor substrate 100 and the finstructures 102N₁, 102N₂, 102P₁, and 102P₂. In some embodiments, the gatedielectric material and the gate electrode layer are sequentiallydeposited by using suitable deposition methods. The suitable depositionmethods may include a chemical vapor deposition (CVD) process, an atomiclayer deposition (ALD) process, a thermal oxidation process, a physicalvapor deposition (PVD) process, another applicable process, or acombination thereof. Afterwards, with the assistance of the hard mask110, the gate dielectric material and the gate electrode layer arepatterned to form the gate stacks including the gate dielectric layer106 and the gate electrode 108.

As shown in FIGS. 1B, 3A and 3B, a mask layer 113 is formed over thegate stack 104P and the fin structures 102P₁ and 102P₂, in accordancewith some embodiments. Therefore, the gate stack 104P and the finstructures 102P₁ and 102P₂ are blocked and protected from beingnegatively affected during subsequent processes performed to the finstructures 102N₁ and 102N₂. In some embodiments, the mask layer 113 ismade of a dielectric material. The dielectric material may includesilicon nitride, silicon oxynitride, silicon carbide, another suitabledielectric material, or a combination thereof.

In some embodiments, a mask material layer is deposited over thesemiconductor substrate 100, the fin structures 102N₁, 102N₂, 102P₁, and102P₂, and the gate stacks 104N and 104P. The mask material layer may bedeposited by using a chemical vapor deposition (CVD) process, a physicalvapor deposition (PVD) process, a spin-on process, another applicableprocess, or a combination thereof. Afterwards, the mask material layeris partially removed by using a photolithography process and an etchingprocess. For example, a patterned photoresist layer (not shown) isformed on the mask material layer. The portion of the mask materiallayer not covered by the photoresist layer is etched. As a result, themask layer 113 is formed.

As shown in FIGS. 1B and 3A, spacer elements 112A are formed oversidewalls of the gate stack 104N, in accordance with some embodiments.The spacer elements 112A may be used to assist in the formation ofsource and drain structures (or regions) in subsequent processes. Insome embodiments, the spacer elements 112A are made of silicon nitride,silicon oxynitride, silicon carbide, another suitable material, or acombination thereof.

In some embodiments, a spacer layer is deposited over the semiconductorsubstrate 100, the fin structures 102N₁, 102N₂, 102P₁, and 102P₂, andthe gate stacks 104N and 104P. The spacer layer may be deposited using aCVD process, a PVD process, a spin-on process, another applicableprocess, or a combination thereof. Afterwards, an etching process, suchas an anisotropic etching process, is performed to partially remove thespacer layer. As a result, the remaining portions of the spacer layerover the sidewalls of the gate stack 104N form the spacer elements 112A.

As shown in FIGS. 3A and 3B, support elements 112B are formed oversidewalls of the fin structures 102N₁ and 102N₂, in accordance with someembodiments. The support elements 112B may be used to assist in thegrowth of source and drain structures (or regions) in subsequentprocesses. In some embodiments, the support elements 112B are made ofsilicon nitride, silicon oxynitride, silicon carbide, another suitablematerial, or a combination thereof.

In some embodiments, a material layer is deposited over thesemiconductor substrate 100, the fin structures 102N₁, 102N₂, 102P₁, and102P₂, and the gate stacks 104N and 104P. The material layer may bedeposited using a CVD process, a PVD process, a spin-on process, anotherapplicable process, or a combination thereof. Afterwards, an etchingprocess, such as an anisotropic etching process, is performed topartially remove the material layer. As a result, the remaining portionsof the material layer over the sidewalls of the fin structures 102N₁ and102N₂ form the support elements 112B.

In some embodiments, the mask layer 113, the spacer elements 112A, andthe support elements 112B are portions of the same dielectric layer. Insome embodiments, a dielectric layer is deposited over the semiconductorsubstrate 100, the fin structures 102N₁, 102N₂, 102P₁, and 102P₂, andthe gate stacks 104N and 104P. In some embodiments, the dielectric layeris deposited using a CVD process, a PVD process, a spin-on process,another applicable process, or a combination thereof. In someembodiments, the dielectric layer includes multiple sub-layers.

Afterwards, a patterned photoresist layer (not shown) is formed over theportion of dielectric layer on the gate stack 104P and the finstructures 102P₁ and 102P₂. An anisotropic etching process is thenperformed to etch back the portion of the dielectric layer not coveredby the photoresist layer. As a result, the remaining portions of thedielectric layer over the sidewalls of the gate stack 104N form thespacer elements 112A. The remaining portions of the dielectric layerover the sidewalls of the fin structures 102N1 and 102N2 form thesupport elements 112B. The remaining portion of the dielectric layerunder the photoresist layer forms the mask layer 113. In these cases,the spacer elements 112A, the support elements 112B, and the mask layer113 are made of the same material. In some embodiments, the photoresistlayer is removed after the formation of the spacer elements 112A and thesupport elements 112B.

Embodiments of the disclosure have many variations and are not limitedto the embodiments mentioned above. In some embodiments, the spacerelements 112A are not formed. In some other embodiments, the supportelements 112B are not formed. In some other embodiments, neither thespacer elements 112A nor the support elements 112B are formed.

As shown in FIGS. 1B, 4A, and 4B, a portion of the fin structures 102N₁and 102N₂ are removed to lower the fin structures 102N₁ and 102N₂ andform recesses 114, in accordance with some embodiments. During therecessing of the fin structures 102N₁ and 102N₂, the fin structures102P₁ and 102P₂ are blocked or protected by the mask layer 113.Therefore, the fin structures 102P₁ and 102P₂ are prevented from beingdamaged.

In some embodiments, the fin structures 102N₁ and 102N₂ are recessed toa level below the tops of the support elements 112B. In someembodiments, the fin structures 102N₁ and 102N₂ are recessed to a levelbelow the top surfaces of the isolation features 103. In someembodiments, an etching process is used to form the recesses 114.However, it should be appreciated that embodiments of the disclosurehave many variations. In some other embodiments, the fin structures102N₁ and 102N₂ are not partially removed to form the recesses 114.

As shown in FIGS. 1C, 5A, and 5B, source/drain structures 116N₁ and116N₂ are respectively formed over the fin structures 102N₁ and 102N₂,in accordance with some embodiments. In some embodiments, asemiconductor material is epitaxially grown in the recesses 114 andcontinues to grow to above the recesses 114 to form the source/drainstructures 116N₁ and 116N₂. The support elements 112B may act as atemplate to control the growth of the source/drain structures 116N₁ and116N₂. As shown in FIGS. 1C, 5A, and 5B, the support elements 112B coverlower portions of the source/drain structures 116N₁ and 116N₂. In someembodiments, the support elements 112B are in direct contact with thesource/drain structures 116N₁ and 116N₂.

During the growth of the source/drain structures 116N₁ and 116N₂, thefin structures 102P₁ and 102P₂ are blocked or protected by the masklayer 113 in some embodiments. Therefore, the semiconductor material isprevented from being grown on the fin structures 102P₁ and 102P₂.

In some embodiments, the source/drain structures 116N₁ and 116N₂protrude above the support elements 112B. The source/drain structures116N₁ and 116N₂ may alternatively be referred to as raised source anddrain features. In some embodiments, the source/drain structures 116N₁and 116N₂ are strained structures. The source/drain structures 116N₁ and116N₂ impart stress or strain to the channel region under the gate stack104N to enhance the carrier mobility of the device and improve deviceperformance.

In some embodiments, the source/drain structures 116N₁ and 116N₂ are ann-type semiconductor material. The source/drain structures 116N₁ and116N₂ may include epitaxially grown silicon, epitaxially grown siliconphosphide (SiP), or another suitable epitaxially grown semiconductormaterial. The source/drain structures 116N₁ and 116N₂ are not limited tobeing an n-type semiconductor material. In some other embodiments, thesource/drain structures 116N₁ and 116N₂ are a p-type semiconductormaterial. For example, the structures 116N₁ and 116N₂ may includeepitaxially grown silicon germanium.

In some embodiments, the source/drain structures 116N₁ and 116N₂ areformed by using a selective epitaxial growth (SEG) process, a CVDprocess (e.g., a vapor-phase epitaxy (VPE) process, a low pressurechemical vapor deposition (LPCVD) process, and/or an ultra-high vacuumCVD (UHV-CVD) process), a molecular beam epitaxy process, anotherapplicable process, or a combination thereof. The formation process ofthe source/drain structures 116N₁ and 116N₂ may use gaseous and/orliquid precursors, which may interact with the composition of the finstructures 102N₂ and 102N₁ thereunder.

In some embodiments, the source/drain structures 116N₁ and 116N₂ aredoped with one or more suitable dopants. For example, the source/drainstructures 116N₁ and 116N₂ are Si source/drain features doped withphosphor (P), antimony (Sb), or another suitable dopant. Alternatively,the source/drain structures 116N₁ and 116N₂ are SiGe source/drainfeatures doped with boron (B) or another suitable dopant.

In some embodiments, the source/drain structures 116N₁ and 116N₂ aredoped in-situ during the growth of the source/drain structures 116N₁ and116N₂. In some other embodiments, the source/drain structures 116N₁ and116N₂ are not doped during the growth of the source/drain structures116N1 and 116N₂. After the formation of the source/drain structures116N₁ and 116N₂, the source/drain structures 116N₁ and 116N₂ are dopedin a subsequent process. In some embodiments, the doping is achieved byusing an ion implantation process, a plasma immersion ion implantationprocess, a gas and/or solid source diffusion process, another applicableprocess, or a combination thereof. In some embodiments, the source/drainstructures 116N₁ and 116N₂ are further exposed to annealing processes toactivate the dopants. For example, a rapid thermal annealing process isperformed.

As shown in FIGS. 1C, 6A, and 6B, a semiconductor protection layer 118is formed over the source/drain structures 116N₁ and 116N₂, inaccordance with some embodiments. The semiconductor protection layer 118is used to protect the source/drain structures 116N₁ and 116N₂ fromdamage during subsequent processes such as cleaning processes and/oretching processes. Therefore, the sizes or morphology of thesource/drain structures 116N₁ and 116N₂ could be maintained after thesubsequent cleaning processes and/or etching processes. The performanceand reliability of the semiconductor device are improved.

In some embodiments, the semiconductor protection layer 118 includescarbon. In some embodiments, the semiconductor protection layer 118 hasan atomic concentration of carbon greater than that of the source/drainstructures 116N₁ or 116N₂. In some other embodiments, the atomicconcentration of carbon is in a range from about 1% to about 10%. Insome other embodiments, the atomic concentration of carbon is in a rangefrom about 1.5% to about 4%. In some cases, if the atomic concentrationof carbon is less than about 1%, the semiconductor protection layer 118might not be able to sustain the subsequent cleaning processes and/oretching processes. As a result, the source/drain structures 116N₁ or116N₂ thereunder may be damaged.

In some embodiments, the semiconductor protection layer 118 has avarying or gradient concentration profile. In some embodiments, theatomic concentration of carbon in the semiconductor protection layer 118gradually decreases along a direction from a surface 119 of thesemiconductor protection layer 118 towards the source/drain structures116N₁ or 116N₂.

In some embodiments, the source/drain structures 116N₁ or 116N₂ are ann-type semiconductor material. In these cases, the semiconductorprotection layer 118 may include a silicon layer doped with carbon or agermanium layer doped with carbon. In some embodiments, the source/drainstructures 116N₁ or 116N₂ are a p-type semiconductor material. In thesecases, the semiconductor protection layer 118 may include a silicongermanium layer doped with carbon.

The thickness of the semiconductor protection layer 118 should be finelycontrolled. In some embodiments, the semiconductor protection layer 118has a thickness in a range from about 2 nm to about 10 nm. In somecases, if the thickness of the semiconductor protection layer 118 issmaller than about 2 nm, the semiconductor protection layer 118 mightnot be able to prevent the source/drain structures 116N₁ and 116N₂ frombeing damaged by the subsequent cleaning processes and/or etchingprocesses. In some other cases, if the thickness of the semiconductorprotection layer 118 is greater than about 10 nm, the electrical qualityof the semiconductor device might be negatively affected.

However, it should be appreciated that embodiments of the disclosure arenot limited to the embodiments mentioned above. In some otherembodiments, the semiconductor protection layer 118 has a thickness in arange from about 0.5 nm to about 15 nm.

In some embodiments, the semiconductor protection layer 118 isepitaxially grown on the source/drain structures 116N₁ and 116N₂.Therefore, the semiconductor protection layer 118 is in direct contactwith the source/drain structures 116N₁ and 116N₂. In some embodiments,the semiconductor protection layer 118 covers the exposed surfaces ofthe source/drain structures 116N₁ and 116N₂. In some embodiments, thesemiconductor protection layer 118 does not cover the lower portions ofthe source/drain structures 116N₁ and 116N₂ which have been covered bythe support elements 112B.

In some embodiments, the semiconductor protection layer 118 is formed byusing a selective epitaxial growth (SEG) process, a CVD process (e.g., avapor-phase epitaxy (VPE) process, a low pressure chemical vapordeposition (LPCVD) process, and/or an ultra-high vacuum CVD (UHV-CVD)process), a molecular beam epitaxy process, another applicable process,or a combination thereof. The formation process of the semiconductorprotection layer 118 may use gaseous and/or liquid precursors, which mayinteract with the composition of the source/drain structures 116N₁ and116N₂ thereunder. The precursor used for forming the semiconductorprotection layer 118 may include SiH₂Cl₂, SiH₄, Si₂H₆, Si₃H₈, GeH₄,SiH₃CH₃, another suitable precursor, or a combination thereof. Byfine-tuning the parameters of the process, the composition of thesemiconductor protection layer 118 may be varied to meet requirements.

In some embodiments, the source/drain structures 116N₁ and 116N₂ and thesemiconductor protection layer 118 are formed in-situ in the sameprocess chamber. FIG. 10 is a cross-sectional view of a process chamber302, in accordance with some embodiments. In some embodiments, both thesource/drain structures 116N₁ and 116N₂ and the semiconductor protectionlayer 118 are formed in the process chamber 302. In some embodiments,the structure shown in FIG. 1B is transferred into the process chamber302 for forming the source/drain structures 116N₁ and 116N₂. After theformation of the source/drain structures 116N₁ and 116N₂, thesemiconductor substrate 100 is not taken out of the process chamber 302.One or more parameters (such as the precursor gas) of the process arethen varied to directly grow the semiconductor protection layer 118 onthe exposed surfaces of the source/drain structures 116N₁ and 116N₂.

As shown in FIGS. 1D, 7A, and 7B, a mask layer 120 is formed over thegate stack 104N, the semiconductor protection layer 118, and the supportelements 112B, in accordance with some embodiments. The mask layer 120has an opening which exposes the mask layer 113 over the gate stack 104Pand the fin structures 102P₁ and 102P₂. Therefore, the gate stack 104Nand the semiconductor protection layer 120 are blocked and protectedfrom being negatively affected during subsequent processes performed onthe fin structures 102P₁ and 102P₂. In some embodiments, the mask layer120 is made of a dielectric material. The dielectric material mayinclude silicon nitride, silicon oxynitride, silicon carbide, anothersuitable dielectric material, or a combination thereof. The mask layer120 may be formed by using a method similar to that used for forming themask layer 113.

Afterwards, as shown in FIGS. 1D and 7A, spacer elements 122 are formedover sidewalls of the gate stack 104P, in accordance with someembodiments. The material and formation method of the spacer elements122 may be similar to those of the spacer elements 112A. For example, aphotoresist layer (not shown) is used to pattern the mask layer 120. Thepatterned mask layer 120 has an opening which exposes the mask layer 113(see FIG. 1C or 6A). In some embodiments, an anisotropic etching processis performed to partially remove the exposed mask layer 113. As aresult, the spacer elements 122 are formed. In some embodiments, due tothe photoresist layer, the mask layer 120 is not etched during theformation of the spacer elements 122, as shown in FIG. 7B. Afterwards,the photoresist layer is removed in some embodiments.

In some embodiments, the portion of the mask layer 113 originallypositioned over the sidewalls of the fin structures 102P₁ and 102P₂ isremoved after the formation of the spacer elements 122. There is nosupport element formed over the sidewalls of the fin structures 102P₁and 102P₂. However, it should be appreciated that embodiments of thedisclosure are not limited thereto. In some other embodiments, supportelements similar to the support elements 112B are formed over thesidewalls of the fin structures 102P₁ and 102P₂.

As shown in FIGS. 1D and 7A, portions of the fin structures 102P₁ and102P₂ are removed to lower the fin structures 102P₁ and 102P₂ and formrecesses 124, in accordance with some embodiments. During the recessingof the fin structures 102P₁ and 102P₂, the semiconductor protectionlayer 118 over the source/drain structures 116N₁ and 116N₂ are blockedor protected by the mask layer 120, as shown in FIGS. 1D, 7A, and 7B.Therefore, the semiconductor protection layer 118 is prevented frombeing damaged.

In some embodiments, the fin structures 102P₁ and 102P₂ are recessed toa level below the tops of the isolation features 103. In someembodiments, an etching process is used to form the recesses 124.Embodiments of the disclosure have many variations. In some otherembodiments, the fin structures 102P₁ and 102P₂ are not partiallyremoved to form the recesses 124.

As shown in FIGS. 1E and 8A, source/drain structures 126P₁ and 126P₂ areformed respectively over the fin structures 102P₁ and 102P₂, inaccordance with some embodiments. In some embodiments, a semiconductormaterial is epitaxially grown in and over the recesses 124 to form thesource/drain structures 126P₁ and 126P₂. In some embodiments, no supportelement is used to assist in the growth of the source/drain structures126P₁ and 126P₂. In some other embodiments, support elements are used.

During the growth of the source/drain structures 126P₁ and 126P₂, thesemiconductor protection layer 118 is blocked or protected by the masklayer 120 in some embodiments. Therefore, the semiconductor material isprevented from being grown on the semiconductor protection layer 118.

In some embodiments, the source/drain structures 126P₁ and 126P₂protrude above the isolation features 103. The source/drain structures126P₁ and 126P₂ may alternatively be referred to as raised source anddrain features. In some embodiments, the source/drain structures 126P₁and 126P₂ are strained structures. The source/drain structures 126P₁ and126P₂ impart stress or strain to the channel region under the gate stack104P to enhance carrier mobility of the device and improve deviceperformance.

In some embodiments, the source/drain structures 126P₁ and 126P₂ are ap-type semiconductor material. The source/drain structures 126P₁ and126P₂ may include epitaxially grown silicon germanium. The source/drainstructures 126P₁ and 126P₂ are not limited to being a p-typesemiconductor material. In some other embodiments, the source/drainstructures 126P₁ and 126P₂ are an n-type semiconductor material. Forexample, the structures 126P₁ and 126P₂ may include epitaxially grownsilicon, epitaxially grown silicon phosphide (SiP), or another suitableepitaxially grown semiconductor material.

In some embodiments, the source/drain structures 126P₁ and 126P₂ areformed by using a selective epitaxial growth (SEG) process, a CVDprocess (e.g., a vapor-phase epitaxy (VPE) process, a low pressurechemical vapor deposition (LPCVD) process, and/or an ultra-high vacuumCVD (UHV-CVD) process), a molecular beam epitaxy process, anotherapplicable process, or a combination thereof. The formation process ofthe source/drain structures 126P₁ and 126P₂ may use gaseous and/orliquid precursors, which may interact with the composition of the finstructures 102P₂ and 102P₁ thereunder.

In some embodiments, the source/drain structures 126P₁ and 126P₂ aredoped with one or more suitable dopants. For example, the source/drainstructures 126P₁ and 126P₂ are SiGe source/drain features doped withboron (B) or another suitable dopant. Alternatively, the source/drainstructures 126P₁ and 126P₂ are Si source/drain features doped withphosphor (P), antimony (Sb), or another suitable dopant.

In some embodiments, the source/drain structures 126P₁ and 126P₂ aredoped in-situ during the growth of the source/drain structures 126P₁ and126P₂. In some other embodiments, the source/drain structures 126P₁ and126P₂ are not doped during the growth of the source/drain structures126P₁ and 126P₂. After the formation of the source/drain structures126P₁ and 126P₂, the source/drain structures 126P₁ and 126P₂ are dopedin a subsequent process. In some embodiments, the doping is achieved byusing an ion implantation process, a plasma immersion ion implantationprocess, a gas and/or solid source diffusion process, another applicableprocess, or a combination thereof. In some embodiments, the source/drainstructures 126P₁ and 126P₂ are further exposed to annealing processes toactivate the dopants. For example, a rapid thermal annealing process isperformed.

As shown in FIGS. 1E, 8A, and 8B, a semiconductor protection layer 128is formed over the source/drain structures 126P₁ and 126P₂, inaccordance with some embodiments. The semiconductor protection layer 128is used to protect the source/drain structures 126P₁ and 126P₂ frombeing damaged during subsequent processes such as cleaning processesand/or etching processes. Therefore, the sizes or morphology of thesource/drain structures 126P₁ and 126P₂ could be maintained after thesubsequent cleaning processes and/or etching processes. The performanceand reliability of the semiconductor device are improved.

In some embodiments, the semiconductor protection layer 128 covers agreater surface area of the source/drain structures 126P₁ and 126P₂ whencompared with the semiconductor protection layer 118. In some otherembodiments, support elements (not shown) are formed to assist in theformation of the source/drain structures 126P₁ and 126P₂. In thesecases, both of the semiconductor protection layers 128 and 118 may coversimilar surface areas of the corresponding source/drain structures.

In some embodiments, the semiconductor protection layer 128 includescarbon. In some embodiments, the semiconductor protection layer 128 ismade of a material similar to that of the semiconductor protection layer118. In some embodiments, the materials of the semiconductor protectionlayers 118 and 128 are the same. In some other embodiments, thematerials of the semiconductor protection layers 118 and 128 aredifferent. In some embodiments, the semiconductor protection layer 118includes silicon and carbon. In some embodiments, the semiconductorprotection layer 128 includes silicon, carbon, and germanium.

In some embodiments, the semiconductor protection layer 128 has avarying or gradient concentration profile. In some embodiments, theatomic concentration of carbon in the semiconductor protection layer 128gradually decreases along a direction from a surface of thesemiconductor protection layer 128 towards the source/drain structures126P₁ or 126P₂.

The thickness of the semiconductor protection layer 128 should be finelycontrolled. In some embodiments, the semiconductor protection layer 128has a thickness in a range from about 2 nm to about 10 nm. In somecases, if the thickness of the semiconductor protection layer 128 isless than about 2 nm, the semiconductor protection layer 128 might notbe able to protect the source/drain structures 126P₁ and 126P₂ frombeing damaged by the subsequent cleaning processes and/or etchingprocesses. In some other cases, if the thickness of the semiconductorprotection layer 128 is greater than about 10 nm, the electrical qualityof the semiconductor device might be negatively affected.

However, it should be appreciated that embodiments of the disclosure arenot limited to the embodiments mentioned above. In some otherembodiments, the semiconductor protection layer 128 has a thickness in arange from about 0.5 nm to about 15 nm.

In some embodiments, the semiconductor protection layer 128 isepitaxially grown on the source/drain structures 126P₁ and 126P₂.Therefore, the semiconductor protection layer 128 is in direct contactwith the source/drain structures 126P₁ and 126P₂. In some embodiments,the semiconductor protection layer 128 covers the exposed surfaces ofthe source/drain structures 126P₁ and 126P₂. In some embodiments, thesemiconductor protection layer 128 cover the lower portions of thesource/drain structures 126P₁ and 126P₂ above the isolation features103.

In some embodiments, the semiconductor protection layer 128 is formed byusing a selective epitaxial growth (SEG) process, a CVD process (e.g., avapor-phase epitaxy (VPE) process, a low pressure chemical vapordeposition (LPCVD) process, and/or an ultra-high vacuum CVD (UHV-CVD)process), a molecular beam epitaxy process, another applicable process,or a combination thereof. The formation process of the semiconductorprotection layer 128 may use gaseous and/or liquid precursors, which mayinteract with the composition of the source/drain structures 126P₁ and126P₂ thereunder. The precursor used for forming the semiconductorprotection layer 128 may include SiH₂Cl₂, SiH₄, Si₂H₆, Si₃H₈, GeH₄,SiH₃CH₃, another suitable precursor, or a combination thereof. Byfine-tuning the parameters of the process, the composition of thesemiconductor protection layer 128 may be varied to meet requirements.In some embodiments, the source/drain structures 126P₁ and 126P₂ and thesemiconductor protection layer 128 are formed in-situ in the sameprocess chamber.

Afterwards, as shown in FIGS. 1F, 9A, and 9B, the mask layer 120 isremoved to expose the gate stack 104N and the semiconductor protectionlayer 118, in accordance with some embodiments. In some embodiments, anetching process is used to remove the mask layer 120. The etchingprocess may include a wet etching process, a dry etching process, or acombination thereof. Due to the semiconductor protection layers 118 and128, the source/drain structures 116N₁, 116N₂, 126P₁, and 126P₂ areprotected without being damaged or without being seriously damagedduring the etching process and/or other associated cleaning processes.The performance and reliability of the semiconductor device areimproved.

Afterwards, various processes may be performed to finish the formationof the semiconductor device. The processes include, for example, acontact hole formation process, a metal silicidation process, a gatereplacement process, another suitable process, or a combination thereof.These processes may involve applying etchants and/or cleaning chemicalsover the source/drain structures 116N₁, 116N₂, 126P₁, and 126P₂. Inthese cases, the semiconductor protection layers 118 and/or 128 arecapable of protecting the structures thereunder from being damaged. Theperformance and reliability of the semiconductor device are improved.

In some embodiments, a portion of the semiconductor protection layers118 or 128 is thinner than the other portions of the semiconductorprotection layers 118 or 128. For example, the portion of thesemiconductor protection layers 118 or 128 exposed by contact holes maybe thinner. The exposed portion of the semiconductor protection layers118 or 128 may be damaged or consumed after the etching processes and/orcleaning processes. As a result, some portions of the semiconductorprotection layers 118 or 128 may be thinner.

FIG. 11 is a cross-sectional view of a stage of a process for forming asemiconductor device, in accordance with some embodiments. The structureshown in FIG. 11 may be formed by using the methods described in FIGS.1A-1F, 2A-9A, and 2B-9B. In some embodiments, a dielectric layer 402 isdeposited and patterned to form a contact hole 404. The right side ofFIG. 11 shows the portion of the semiconductor protection layer 118covered by the dielectric layer 402. The left side of FIG. 11 shows theportion of the semiconductor protection layer (which is denoted byreference number 118′) exposed by the contact hole 404. In someembodiments, the portion of the semiconductor protection layer 118′ isthinner than the portion of the semiconductor protection layer 118covered by the dielectric layer 402. In these cases, a first portion thesemiconductor protection layer 118 or 128 is thinner than a secondportion of the semiconductor protection layer 118 or 128. In someembodiments, the first portion is under a contact hole.

However, it should be appreciated that embodiments of the disclosure arenot limited to the embodiments mentioned above. In some embodiments, theportion of the semiconductor protection layer 118′ exposed by thecontact hole 404 has a thickness substantially equal to that of thesemiconductor protection layer 118 not exposed by the contact hole 404.In these cases, the etching and/or cleaning processes for forming thecontact hole 404 does not substantially damage or consume the exposedsemiconductor protection layer 118.

Embodiments of the disclosure provide a structure and formation methodof a semiconductor device with a fin structure (or a raised source/drainstructure). A semiconductor protection layer is formed over the finstructure. The semiconductor protection layer could be grown in-situ onthe fin structure. The semiconductor protection layer includes carbonand has an atomic concentration of carbon greater than that of theunderlying fin structure. The semiconductor protection layer can protectthe fin structure from being damaged or being seriously damaged duringsubsequent processes such as etching and/or cleaning processes.Therefore, the performance and reliability of the semiconductor deviceare improved.

In accordance with some embodiments, a semiconductor device is provided.The semiconductor device includes a semiconductor substrate and a finstructure over the semiconductor substrate. The semiconductor devicealso includes a gate stack covering a portion of the fin structure andan epitaxially grown source/drain structure over the fin structure andadjacent to the gate stack. The semiconductor device further includes asemiconductor protection layer over the epitaxially grown source/drainstructure. The semiconductor protection layer has an atomicconcentration of carbon greater than that of the epitaxially grownsource/drain structure.

In accordance with some embodiments, a semiconductor device is provided.The semiconductor device includes a semiconductor substrate and a firstfin structure over the semiconductor substrate. The semiconductor devicealso includes a first epitaxially grown source/drain structure over thefirst fin structure. The semiconductor device further includes a secondfin structure over the semiconductor substrate and a second epitaxiallygrown source/drain structure over the second fin structure. In addition,the semiconductor device includes a first semiconductor protection layerover the first epitaxially grown source/drain structure, and the firstsemiconductor protection layer has an atomic concentration of carbongreater than that of the first epitaxially grown source/drain structure.The semiconductor device further includes a second semiconductorprotection layer over the second epitaxially grown source/drainstructure, and the second semiconductor protection layer has an atomicconcentration of carbon greater than that of the second epitaxiallygrown source/drain structure.

In accordance with some embodiments, a method for forming asemiconductor device is provided. The method includes forming a finstructure over a semiconductor substrate and forming a gate stack overthe semiconductor substrate and covering a portion of the fin structure.The method also includes epitaxially growing source/drain structuresover the fin structure and adjacent to the gate stack. The methodfurther includes forming a semiconductor protection layer over thesource/drain structures. The semiconductor protection layer includescarbon.

The foregoing outlines features of several embodiments so that thoseskilled in the art may better understand the aspects of the presentdisclosure. Those skilled in the art should appreciate that they mayreadily use the present disclosure as a basis for designing or modifyingother processes and structures for carrying out the same purposes and/orachieving the same advantages of the embodiments introduced herein.Those skilled in the art should also realize that such equivalentconstructions do not depart from the spirit and scope of the presentdisclosure, and that they may make various changes, substitutions, andalterations herein without departing from the spirit and scope of thepresent disclosure.

What is claimed is:
 1. A semiconductor device structure, comprising: asemiconductor substrate; a fin structure over the semiconductorsubstrate; a gate stack covering a portion of the fin structure; anepitaxially grown source/drain structure over the fin structure andadjacent to the gate stack; and a semiconductor protection layer overthe epitaxially grown source/drain structure, wherein the semiconductorprotection layer has an atomic concentration of carbon greater than thatof the epitaxially grown source/drain structure.
 2. The semiconductordevice as claimed in claim 1, wherein the semiconductor protection layeris in direct contact with the epitaxially grown source/drain structure.3. The semiconductor device as claimed in claim 1, wherein thesemiconductor protection layer includes silicon and carbon.
 4. Thesemiconductor device as claimed in claim 1, wherein the semiconductorprotection layer includes silicon, carbon, and germanium.
 5. Thesemiconductor device as claimed in claim 1, wherein the atomicconcentration of carbon in the semiconductor protection layer is in arange from about 1% to about 10%.
 6. The semiconductor device as claimedin claim 1, wherein the atomic concentration of carbon in thesemiconductor protection layer gradually decreases along a directionfrom a surface of the semiconductor protection layer towards theepitaxially grown source/drain structure.
 7. The semiconductor device asclaimed in claim 1, wherein the epitaxially grown source/drain structureis an n-type semiconductor material.
 8. The semiconductor device asclaimed in claim 1, wherein the epitaxially grown source/drain structureis a p-type semiconductor material.
 9. The semiconductor device asclaimed in claim 1, further comprising support elements covering a lowerportion of the epitaxially grown source/drain structure, wherein thesupport elements are in direct contact with the epitaxially grownsource/drain structure, and the support elements are between thesemiconductor protection layer and the semiconductor substrate.
 10. Thesemiconductor device as claimed in claim 1, wherein the semiconductorprotection layer has a first portion and a second portion, and the firstportion is thinner than the second portion.
 11. A semiconductor device,comprising: a semiconductor substrate; a first fin structure over thesemiconductor substrate; a first epitaxially grown source/drainstructure over the first fin structure; a second fin structure over thesemiconductor substrate; a second epitaxially grown source/drainstructure over the second fin structure; a first semiconductorprotection layer over the first epitaxially grown source/drainstructure, wherein the first semiconductor protection layer has anatomic concentration of carbon greater than that of the firstepitaxially grown source/drain structure; and a second semiconductorprotection layer over the second epitaxially grown source/drainstructure, wherein the second semiconductor protection layer has anatomic concentration of carbon greater than that of the secondepitaxially grown source/drain structure.
 12. The semiconductor deviceas claimed in claim 11, wherein the first semiconductor protection layerand the second semiconductor protection layer are made of differentmaterials.
 13. The semiconductor device as claimed in claim 11, whereinthe atomic concentration of carbon in the first semiconductor protectionlayer or the second semiconductor protection layer is in a range fromabout 1% to about 10%.
 14. The semiconductor device as claimed in claim11, wherein the atomic concentration of carbon in the firstsemiconductor protection layer gradually decreases along a directionfrom a surface of the first semiconductor protection layer towards thefirst epitaxially grown source/drain structure.
 15. The semiconductordevice as claimed in claim 11, wherein the first epitaxially grownsource/drain structure is an n-type semiconductor material, and thesecond epitaxially grown source/drain structure is a p-typesemiconductor material.
 16. A method for forming a semiconductor device,comprising: forming a fin structure over a semiconductor substrate;forming a gate stack over the semiconductor substrate and covering aportion of the fin structure; epitaxially growing source/drainstructures over the fin structure and adjacent to the gate stack; andforming a semiconductor protection layer over the source/drainstructures, wherein the semiconductor protection layer comprises carbon.17. The method for forming a semiconductor device as claimed in claim16, wherein the semiconductor protection layer is epitaxially grown onthe source/drain structures.
 18. The method for forming a semiconductordevice as claimed in claim 16, wherein the source/drain structures andthe semiconductor protection layer are formed in-situ in a same processchamber.
 19. The method for forming a semiconductor device as claimed inclaim 16, further comprising: forming a second fin structure over thesemiconductor substrate; forming a second gate stack over thesemiconductor substrate and covering a portion of the second finstructure; blocking the second fin structure before the epitaxiallygrown source/drain structures and the semiconductor protection layer areformed; epitaxially growing second source/drain structures over thesecond fin structure and adjacent to the second gate stack; and blockingthe semiconductor protection layer before the second source/drainstructures are formed.
 20. The method for forming a semiconductor deviceas claimed in claim 19, further comprising forming a secondsemiconductor protection layer over the second source/drain structuresafter the blocking of the semiconductor protection layer.